Puffed fabrics



H. P, FARHS ET PUF'FED FABRICS ,mmw

Filed March 3.1, .1955

2 Sheets-Sheet l JNVENTORS 00061.43 D. Mc Germ HAROLD P. FARl-fi M"BEIJQNARB R- ZEN H. W. FAWHE ET PUFFED FABRICS Film March 33.. 1955 P.Shee'ts-Shaet P United States Patent PUFFED FABRICS Harold P. Faris,Philadelphia, PZL, and Bernard R. Koenig,

Oswego, Oreg., assignors to Chicopee Manufacturing Corporation, ChicopeeFalls, Mass, a corporation of Massachusetts Application March 31, 1955,Serial No. 498,306

5 Claims. (Ci. 28--78) The present invention relates to woven fabricshaving puffed portions to provide patterns thereon of a highlyattractive three-dimensional appearance. The fabrics of the presentinvention are advantageously useful as upholstery fabrics, particularly,automobile upholstery.

Objects and advantages of the invention will beset forth in parthereinafter and in part will be obvious herefrom, or may be learned bypractice with the invention, the same being realized and attained bymeans of the combinations and improvements pointed out in the appendedclaims.

The invention consists in the novel parts, constructions, arrangements,combinations and improvements herein shown and described.

An object of our invention is to provide a woven fabric having puffedportions to provide patterns hav ng an aesthetically superiorappearance, particularly with respect to three-dimensional effect, tothe presently known puifed fabrics.

Another object of my invention is to provide a predominantlythermoplastic fabric having puffed portions wherein the puffs are sharpand accentuated and wherein the puffs retain these desirablecharacteristics after a long period of use.

Woven fabrics having puffed or puckered portions are known. Theheretofore produced puffed fabrics have not been entirely satisfactory,due to the difficulty in producing puffs which are sharp andaccentuated. Also, difiiculties have arisen in retaining the puffed porton when the fabric was in use through shrinkage, wearing, tearing, etc.

In order to overcome the foregoing difiicultres confronting the user ofthe prior puffed fabrics, we have d 1scovered the present invention. Ournovel puffed fabrics possess sharp and accentuated puifs and thepatterns produced by said puffs have a highly attractivethree-dimensional appearance. Advantageousl the puffs of our fabrics arepermanently retained so that the desired pattern design is preservedafter a long period of use.

Our novel pulfed fabrics, having the above-described advantages, areproduced by the utilization of thermoplastic and heat shrinkableshrinkers or floats made of suitable thermoplastic filaments in conunction w th a woven fabric body consisting of filaments of a suitablematerial, preferably thermoplastic. The aforesaid nlaments, whether usedas shrinkers or in the main body of the fabric, may be in the form ofmonofilaments, twisted multifilament strands, yarn spun from filamentstaple, 'etc. The shrinkers are incorporated on the main body of thefabric in such a manner, as will be described n detail hereinbelow, thatpulfs are formed on the main body when the shrinkers are subjected to aheat shrinking treatment.

Accordingly, the shrinkers are attached to the main body of the fabricso that a predominant portion of the shrinkers are floated at the backof the body and are brought to intersect the main body so as to definethe borders of the puffs formed after the fabric body with 2 ,757,437Patented Aug. 7, 1956 attached shrinkers has been subjected to ashrinking step. Hence, the pulfed portions are defined where theshrinkers intersect the main body of the fabric. Moreover, in order thatthe puffs formed be sharp and accentuated, it is preferred that at leastabout of the total lengths of the shrinkers are floated at the back ofthe main body of the fabric. By the term floated, as used herein, ismeant that the shrinkers are not interwoven with the fibers of the mainbody but instead pass over or under a p1urality of threads of the mainbody.

After the shrinkers have been secured to the main body of the fabric inthe foregoing manner, the fabric with attached shrinkers is subjected toa suitable shrinking treatment which varies depending upon whether ornot the main body of the fabric and the shrinkers have the sameshrinkage characteristics. Regardless of the particular heat treatmentthat is employed, the treatment is such that the portion of theshrinkers floated on the back of the fabric shrinks at a faster ratethan the main body of the fabric so as to cause the portion of the bodyof the fabric adjacent thereto to rise, thus forming the desired puffson the front of said fabric body. The body portion of the main bodyadjacent the shrinkers is caused to rise on shrinkage of the shrinkers,due to the grip exerted by the shrinkers on the fibers of the main bodyportion.

As mentioned hereinabove, the particular method of shrinking the floatsor shrinkers depends upon the chemical compositions of the main body andthe shrinkers. For example, if the compositions of the main body andshrinkers or floats have identical shrinkage rates, then the heatingtreatment is such that the temperature on the back side of the fabrichaving the predominant portions of exposed floats is higher than thetemperature at the face of the fabric wherein the only exposed portionsof the shrinkers are those which define the borders of the puffs. Thus,by providing such a heat differential, the exposed portions of theshrinkers on the back of the fabric body will shrink to a greater extentthan the balance of the filaments, that is, the filaments forming themain body of the fabric and the portions of the shrinkers exposed at thefront of the main body, thereby causing the puffed eifect. This heattreatment can be carried out in a number of different ways, such as bypassing the fabric around a plurality of internally heated dry cans, sothat the back side of the fabric always contacts the hot surface asdisclosed in detail in co-pending applicatron Serial No. 498,286, filedMarch 31, 1955 by Douglas D. McCord, Thomas R. Holbrook, and Charles A.Rudolph.

Where the filaments forming the main body of the fabric arethermoplastic and of a different chemical composition than the shrinkingfilaments so as to have different shrinkage characteristics, anyconventional heating step may be used to take advantage of the shrinkagedifferential.

The thermoplastic, heat shrinkable floats, on heating, deform where theyintersect the main body of the fabric, which helps to retain the puffsin their desired form. The retention of the puffs is further enhancedwherein the main body is also thermoplastic, due to the setting orhardening of the main body of the fabric on cooling.

in order to further accentuate and increase the sharpness of the puifs,it is preferred that the shrinkers be floated slightly over the face ofthe fabric. Accordingly, in the preferred construction, a small portionof the shrinkers is floated slightly over the face of the fabric, saidfloated portions defining the borders of the puffs, Wilhihfi remainingpredominant floated portion of the shrinkers being exposed at the backof the fabric. By

sharp characteristics are formed, compared to the puffs that are formedwhen the balance of the shrinkers, outside of the portion floated at theback, is merely interwoven with the fabric body. Also, the appearance ofthe puffed fabric is enhanced since the only portion of the shrinkersthat is seen at the face of the main body is that which defines theborders of the puffs which imparts a most attractive appearance to thefabric, particularly where the filaments forming the main body and thoseforming the shrinkers are of a different color, resulting in anaesthetic two-tone effect.

It should be realized that the shrinkers, floated predominantly on theback of the fabric body, may be secured thereto in a variety ofdirections, depending upon the particular pattern design that isdesired. Thus, the shrinkers may be floated in the warp direction, fillor weft direction, both directions, etc., to produce square, diamond,rectangular, and various other types of patterns.

Typical examples of filaments that may be used in forming the floats orshrinkers of our fabrics include Vinyon, and oriented copolymer of vinylchloride (88 to 90% with vinyl acetate to 12%); oriented polymerizedethylene (polyethylene) and saran copolyrners of vinylidene chloride andvinyl chloride, wherein the vinyl chloride is present in an amount ofabout 18 to 30%. Suitable filaments for forming the main body of thefabric include the saran family of vinylidene chloridevinyl chloridecopolymers, having about 4 to preferably 8 to 12%, vinyl chloride, andDacron, an oriented polyester of tcrcphthalic acid with. ethyleneglycol.

A particularly preferred combination of thermoplastic filaments inproducing our novel puffed fabrics is that disclosed in co-pendingapplication Serial No. 498,199, filed March 31, 1955 by I. FerrellNicholl, utilizing Saran filaments. In this application there isdisclosed a puffed fabric wherein the main body of the fabric is wovenfrom filaments of a saran copolymer, and the shrinking floats are of aslightly different saran copolymer, in which the floats have appreciablyhigher initial shrinking characteristics than the main body, butwherein, after the initial shrinking, the floats or shrinkers have thesame shrinkage characteristics as the main body of the fabric. Anexample of such a combination is where the saran copolymer of the floatscontains about vinyl chloride and the saran copolymer of the main bodycontains about 11% vinyl chloride. By using such a combination of Saranfilaments, the puffed fabrics produced maintain their pattern design inspite of shrinkage, wear, etc., while in use, since all of the filamentsof said fabrics have the same physical properties after the formation ofthe puffs.

In order to described the invention more specifically, reference is nowmade to the accompanying drawings. The accompanying drawings, referredto herein and constituting a part hereof, illustrate three embodimentsof the invention, and together with the description serve to explain theprinciples of the invention.

Fig. 1 is a view of the face of one embodiment of our fabrics, with aminimum of structural detail shown.

Fig. 2 is a View of the back of the fabric of Fig. 1.

Fig. 3 is a greatly enlarged schematic view of the area enclosed by dotand dash lines, as shown in Fig. 1, but before the fabric has beensubjected to the heat shrinking operation.

Fig. 4 is a section along the line 4-4 of Fig. 3.

Fig. 5 is similar to Fig. 4 but indicating the configuration of thefabric after the shrinking operation has taken place.

Figs. 67 are similar to Figs. 1 and 2, but showing a different designpattern.

Figs. 8-9 are similar to Figs. 1 and 2, but showing a still differentdesign pattern.

Referring now to Figs. 1-5, there is illustrated therein one embodimentof our fabrics having puffs 1 forming a diamond pattern which is seenpictorially in Fig. 1. The puffs 1 are produced by incorporating heatshrinkable shrinkers 2 on the main body 3 of a fabric wovenpredominantly from thermoplastic materials, and subsequently subjectingthe fabric to a heating shrinking operation causing the portions 2a ofshrinkers floated on back of the main body to shrink from a positionshown in Fig. 4 to that shown in Fig. 5 to form the desired puffs. Themain body of the fabric may include yarns or filaments of suchconventional textile materials as cotton, viscose or acetate rayon,etc., and may include other materials such as glass or metal.

As seen in Fig. 3, the main body 3 of the fabric is of a wellknown wovenstructure, wherein, looking at the face of the fabric as in Fig. 3, thefiller or weft threads 4 are alternately woven under two and over one ofthe warp threads 5.

As seen in Figs. 2 and 3, the shrinkers 2 are floated, in a weftdirection, predominantly on the back side 6 of the main body 2. Theshrinker portions 2a floated on the back side of the main body are wovenin a predetermined manner for the purpose of forming diamond-like puffs1 on the front 7 of the main body when the shrinkers are subjected tothe heating shrinking operation. Moreover, as seen in Figs. 1 and 3, theshrinkers 2 are floated slightly over the front face 7 in apredetermined manner whereby the borders of the puffs .l are defined bythe portions 2b of the shrinkers floated on the front face of the mainbody. In order to produce puffs which are accentuated and sharp, theportions 2a of the shrinkers floated at the back constitute at leastabout 75% of the total shrinkage area. As seen in Figs. 1 and 2, theratio of the shrinker area floated at the back (Fig. 2) is predominantlygreater than that floated at the front (Fig. 1). 1

The effect of the shrinking of the shrinker portions 211 on the fabricbody 3 is seen in Figs. 4 and 5. Before shrinkage, the warp threads 5a,under which the shrinker portions 2a pass, form a smooth surface (Fig.4). When the shrinker portions 2a are caused to shrink, however, thewarp threads 50: are pulled together, causing the body portion of thefabric adjacent the shrinker portions 2:: to rise above the front face 7of the'fabric to form the desired puffs 1 (Fig. 5). Also, by floatingthe shrinkers over a number of warp threads 5b, the warp threads So donot rise tangentially from the front face but at an angle, whichcontributes to the formation of sharp and accentuated puffs.

The puffs 1 are retained in the fabric body in use, due to the settingof the main body '7, including the puffed portions after the shrinkingoperations, by the formation of crimps 8 in the floats or shrinkerswhere they intersect the main body and by the adhesion of the floats tothe main body where they intersect said body at points 9. (See Fig. 5.)

In Figs. 67, there is illustrated another embodiment of our inventionwherein the shrinkers have been incorporated in such a manner to producepuffs 2(1) of a polygonal configuration. As in the embodiment of Figs.1-5, the shrinkers are floated predominantly at the back of the fabric,shrinker portions 2.1a being floated at the back 22 of the main body andshrinker portions 211) being floated slightly over the face 23 of themain body.

A still different embodiment is illustrated in Figs. 8 and 9, whereinthe shrinkers have been incorporated on the main body in such a mannerto produce puffs 30 of a rectangular configuration. As in the foregoingembodiments, the shrinkers are floated predominantly at the back of thefabric, shrinker portions 31a being floated at the back 32 of the mainbody and shrinker portions 31b being floated slightly over the face 33of the main body.

Our novel puffed fabrics as illustrated by the foregoing embodiments areparticularly adapted for use in upholstery, especially automobileupholstery, not only because of their highly attractivethree-dimensional appearance, but also because they possess adequatebreathing properties. By breathing properties is meant that the fabricsare sulficiently porous to permit the passage of air therethrough toprovide adequate ventilation. Thus, they may readily be used as seatcovers without causing discomfort to anyone coming in contact therewith.

The invention in its broader aspects is not limited to the specificcombinations and improvements described, but departures may be madetherefrom within the scope of the accompanying claims without departingfrom the principles of the invention and without sacrificing its chiefadvantages.

We claim:

1. A woven fabric comprising a main body consisting predominantly ofinterwoven thermoplastic Warp and Weft filaments and having sharp andaccentuated puffs which are retained during use of said fabric, andfilaments heatshrunken from thermoplastic heat-shrinkable filamentshaving higher shrinkage characteristics on the application of heat thanthe filaments forming the main body of the fabric, said heat-shrunkenfilaments being floated predominantly on the back of the main body ofsaid fabric and across the puifs.

2. A woven fabric in accordance with claim 1, wherein at least about ofthe total lengths of said heat shrunken filaments are floated on theback of the main body of said fabric.

3. A woven fabric in accordance With claim 1, wherein the heat-shrunkenfilaments intersect said main body to define borders of said puflfs.

4. A woven fabric in accordance with claim 3, wherein short lengths ofthe heat-shrunken filaments are floated over the face of the main bodyof the fabric.

5. A Woven fabric in accordance with claim 1, wherein the main body isheat set.

References Cited in the file of this patent UNITED STATES PATENTS2,332,485 Hanson Oct. 19, 1943 2,401,829 Kahil June 11, 1946 2,401,830Kahil June 11, 1946 2,539,301 Foster June 23, 1951 2,607,104 Foster Aug.19, 1952 2,632,230 Neisler, Jr. Mar. 24, 1953 2,635,648 Foster Apr. 21,1953

1. A WOVEN FABRIC COMPRISING A MAIN BODY CONSISTING PREDOMINANTLY OFINTERWOVEN THERMOPLASTIC WARP AND WEFT FILAMENTS AND HAVING SHARP ANDACCENTUATED PUFFS WHICH ARE RETAINED DURING USE OF SAID FABRIC, ANDFILAMENTS HEATSHRUNKEN FROM THERMOPLASTIC HEAT-SHRINKABLE FILAMENTSHAVING HIGHER SHRINKAGE CHARACTERISTICS ON THE APPLICATION OF HEAT THANTHE FILAMENTS FORMING THE MAIN BODY OF THE FABRIC, SAID HEAT-SHRUNKENFILAMENTS BEING FLOATED PREDOMINANTLY ON THE BACK OF THE MAIN BODY OFSAID FABRIC AND ACROSS THE PUFFS.